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Download 3 HARDWARE AND WIRING - Grupo Feynsa  V APPLICATION AND INSTALLATION MANUAL 3.3 ENGINE HARNESS The Engine Harness (EH) is installed at the factory and is delivered connected to all engine

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  • DDEC V APPLICATION AND INSTALLATION MANUAL

    3 HARDWARE AND WIRING

    Section Page

    3.1 SUPPLIED HARDWARE ......................................................................... 3-3

    3.2 ELECTRONIC CONTROL UNIT ............................................................. 3-5

    3.3 ENGINE HARNESS ................................................................................ 3-11

    3.4 VEHICLE INTERFACE HARNESS ......................................................... 3-15

    3.5 POWER SUPPLY .................................................................................... 3-35

    3.6 FUSES .................................................................................................... 3-37

    3.7 CONNECTORS ....................................................................................... 3-39

    3.8 WIRES AND WIRING ............................................................................. 3-55

    3.9 CONDUIT AND LOOM ............................................................................ 3-81

    3.10 TAPE AND TAPING ................................................................................ 3-83

    3.11 SENSORS ............................................................................................... 3-85

    3.12 THROTTLE DEVICES ............................................................................ 3-117

    3.13 LIGHTS ................................................................................................... 3-121

    All information subject to change without notice. (Rev. 09/05) 3-17SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • HARDWARE AND WIRING

    THIS PAGE INTENTIONALLY LEFT BLANK

    3-2 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • DDEC V APPLICATION AND INSTALLATION MANUAL

    3.1 SUPPLIED HARDWARE

    Original Equipment Manufacturer (OEM) supplied hardware and DDC supplied hardware isrequired to install DDEC V. The following sections list the minimum hardware required.

    3.1.1 OEM-SUPPLIED HARDWARE

    The minimum OEM-supplied hardware required is listed in Table 3-1.

    Hardware Description

    Vehicle Interface Harness (VIH)(refer to section 3.4)

    Connects the vehicle functions and battery power (12/24volts) and ground to the ECU and includes fuse(s) or circuitbreaker(s). Also connects the ECU J1939 node to othervehicle systems.

    Connector Shroud for VIH Connector(refer to section 3.2.1)

    The shroud protects the connectors from dirt and directspray and routes the wires in the correct orientation.

    Throttle Input Device(refer to section 3.12)

    An Accelerator Pedal (AP) with an Idle Validation Switch(required), hand throttle, or alternative throttle device

    Ignition Switch(refer to section 3.4.2) Switched 12 or 24 volt ignition source

    Amber Warning Lamp (AWL)(refer to section 3.13.1) A panel-mounted amber indicator light.

    Red Stop Lamp (RSL)(refer to section 3.13.2) A panel-mounted red indicator light.

    Engine Coolant Level Sensor (ECL Sensor)(refer to section 3.11.20) A radiator top tank- or remote surge tank-mounted sensor

    Diagnostic Connector, Cab (DCC)(refer to section 3.7.3) Cab-mounted diagnostic connector

    Table 3-1 OEM-Supplied Hardware

    3.1.2 DDC-SUPPLIED HARDWARE

    The minimum DDC-supplied hardware required is listed in Table 3-2.

    Hardware Description

    Engine Harness(refer to section 3.3)

    Factory installed harness that facilitates the receipt of input andoutput signals, controlling the fuel injection process and enginespeed. Harness is connected to DDC installed sensors, theinjection unit and the ECU(s).

    Electronic Control Unit (ECU)Refer to section 3.2.

    Engine mounted ECU provides control logic for overall enginemanagement.

    Engine SensorsRefer to section 3.11.1. Various engine mounted sensors for engine control.

    Turbo Compressor In Temperature SensorRefer to section 3.11.23.

    Sensor to measure turbo compressor inlet temperature. MUSTbe installed by the OEM. Series 60 only.

    Table 3-2 Minimum DDC-Supplied Hardware

    All information subject to change without notice. (Rev. 09/05) 3-37SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • HARDWARE AND WIRING

    THIS PAGE INTENTIONALLY LEFT BLANK

    3-4 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • DDEC V APPLICATION AND INSTALLATION MANUAL

    3.2 ELECTRONIC CONTROL UNIT

    The engine-mounted Electronic Control Unit (ECU) (see Figure 3-1) includes control logic toprovide overall engine management. The ECU continuously performs self-diagnostic checksand monitors other system components. System diagnostic checks are made at ignition-on andcontinue throughout all engine-operating modes.

    Figure 3-1 Electronic Control Unit

    The DDEC V ECU has two 68-pin Tyco connectors - one for the engine and the other for thevehicle.

    All information subject to change without notice. (Rev. 09/05) 3-57SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • HARDWARE AND WIRING

    DDEC V supports three independent data links. There are two links on the Vehicle InterfaceHarness (VIH). One link is based on SAE J1708, and the second is SAE J1939. The other link,on the Engine Harness, is CAN based and will be used for proprietary communications such asmulti-ECU applications and DDC factory programming.

    The following warning label is found on the ECU (see Figure 3-2).

    Figure 3-2 ECU Warning Label

    3-6 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • DDEC V APPLICATION AND INSTALLATION MANUAL

    Connector shrouds protect the two 68-pin Tyco connectors (see Figure 3-3).

    Figure 3-3 Electronic Control Unit with Connector ShroudsThe shrouds are fastened to the ECU studs with lock nuts.

    See Figure 3-4 for the ECU outline and dimensions.

    The DDEC V ECU has the same footprint as DDEC II, III, and IV.

    Figure 3-4 Dimensions of Electronic Control Unit with Connector Shrouds

    All information subject to change without notice. (Rev. 09/05) 3-77SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • HARDWARE AND WIRING

    3.2.1 CONNECTOR SHROUD

    The shroud is used to protect the connectors from dirt and direct spray and to route the wires inthe correct orientation. The shroud is designed for 25-30 mm conduit. The shroud is REQUIRED.

    Different views of the connector shroud may be seen in the next illustration (see Figure 3-5).

    Figure 3-5 Electronic Control Unit Connector Shroud

    Two lock nuts are required to attach the shroud to the ECU studs. The torque specification forthe lock nuts is 30 in.lb (3.4 Nm).

    3-8 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • DDEC V APPLICATION AND INSTALLATION MANUAL

    3.2.2 ECU PART NUMBERS

    Part number for the DDEC V ECU is listed in Table 3-3.

    Description Part Number Voltage No. of CylindersDDEC V ECU 23530802 12/24 Volts 6

    Table 3-3 ECU Part Numbers

    The part numbers for the ECU connectors are listed in Table 3-4.

    Description DDC Part Number Tyco Part NumberVehicle Interface HarnessConnector Assembly 23528252 776315-1

    Engine Harness Connector Assembly 23528253 776315-2

    Shroud 23532347 776501-1Shroud Lock Nuts

    (M6x1.0 Nylon Insert Lock NutPlated with Yellow Zinc)

    23533607

    ECU Stud 23533606 14 AWG Terminal (Large)

    (Terminal only) 23528272 776492-1

    18 AWG Terminal (Standard)(Terminal only) 23528271 776326-4

    14 AWG Terminal (Large)(crimped with 12 in. wire) 23528255

    18 AWG Terminal (Standard)(crimped with 12 in. wire) 23528254

    Cavity Plug 23528274 776364

    Table 3-4 ECU Connector Part Numbers

    All information subject to change without notice. (Rev. 09/05) 3-97SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • HARDWARE AND WIRING

    3.2.3 ENVIRONMENTAL CONDITIONS

    The following environmental conditions must be considered.

    Temperature

    The ambient operating temperature range is -40F (-40C) minimum and 221F (105C)maximum.

    Atmospheric Pressure

    The engine-mounted ECU can withstand atmospheric pressures ranging from 62.0 to 120 kPaabsolute that result from altitude and weather changes in the operating and non-operatingconditions.

    Water Intrusion

    The ECU can be exposed to steam cleaning and pressure washing. Care should be taken not topressure spray the connectors.

    3-10 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

  • DDEC V APPLICATION AND INSTALLATION MANUAL

    3.3 ENGINE HARNESSThe Engine Harness (EH) is installed at the factory and is delivered connected to all enginesensors, the fuel injection system and the ECU.

    3.3.1 EH CONNECTOR AND TYPICAL REQUIRED FUNCTIONSThe EH 68-pin Tyco connector pinout for the Series 60 is listed in Table 3-5 and Table 3-6.

    Pin Wire Color Signal Type Function Connector

    E-1 Blk PWM Output Low Side EGR Hydraulic ValveControlE-2 Wht Analog Input 1.5k Pull-up Air Temp

    E-3 Analog Input 51k Pull-down Spare

    E-4 Blk PWM Output Low Side VGT VPOD Control

    E-5 Yel Analog Input 1.5k Pull-up Coolant Temp

    E-6 Analog Input 51k Pull-down Spare

    E-7 Tan Analog Input 1.5k Pull-up Oil Temp

    E-8 PWM Output Low Side Spare

    E-9 Orn Analog Input 1.5k Pull-up Fuel Temp

    E-10 Analog Input 1.5k Pull-up EGR Temp

    E-11 PWM Output Low Side Spare

    E-12 Gra Sensor